B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression

B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools

Abstract

A rotary drill bit is manufactured by a powder metallurgy process by placing a
metal mandrel 54 in a mould 38, packing the mould 38 with particulate matrix-forming
material 50, infiltrating the material with a molten binding alloy, and cooling the
assembly to form a solid infiltrated matrix bonded to the mandrel 54. The mandrel 54
comprises an outer part 56 surrounded by the matrix-forming material 50 and an inner
part 58, secured to the outer part 56 but out of contact with the matrix-forming material
50. The outer part 56 of the mandrel 54 is formed from a material having thermal
characteristics close to those of the matrix, so as to reduce the tendency for the matrix
to crack under the thermal stress, while the inner part 58 of the mandrel 54 is formed
from a precipitation-hardening material, the strength and hardness of which increases in
the infiltration process and the subsequent heating/cooling cycle for brazing the cutters
24 on to the drill bit. A threaded connection region of the drill bit may be formed
directly on the inner part 58 since it will have sufficient strength and hardness for this
purpose.

Description

[0001]

The invention relates to methods of manufacturing rotary drill bits, and
particularly rotary drag-type drill bits of the kind comprising a bit body having a
threaded shank for connection to a drill string and a leading face on which are mounted
a plurality of cutters.

[0002]

The cutters may, for example, be preform cutting elements comprising a layer
of superhard material, such as polycrystalline diamond, bonded to a substrate of less
hard material, such as cemented tungsten carbide. The substrate of the cutting element
may be bonded, for example by brazing, to a carrier which may also be of cemented
tungsten carbide, the carrier then being brazed within a socket on the leading face of the
bit body. Alternatively, the substrate of the cutter may itself be of sufficient size to be
brazed directly within a socket in the bit body.

[0003]

Drag-type drill bits of this kind are commonly of two basic types. The bit body
may be machined from metal, usually steel, and in this case the sockets to receive the
cutters are formed in the bit body by conventional machining processes. The present
invention, however, relates to the alternative method of manufacture where the bit body
is formed using a powder metallurgy process. In this process a metal mandrel is located
within a graphite mould, the internal shape of which corresponds to the desired external
shape of the bit body. The space between the mandrel and the interior of the mould is
packed with a particulate matrix-forming material, such as tungsten carbide particles,
and this material is then infiltrated with a binder alloy, usually a copper alloy, in a furnace
which is raised to a sufficiently high temperature to melt the infiltration alloy and cause
it to infiltrate downwardly through the matrix-forming particles under gravity. The
mandrel and matrix material are then cooled to room temperature so that the infiltrate
solidifies so as to form, with the particles, a solid infiltrated matrix surrounding and
bonded to the metal mandrel.

[0004]

Sockets to receive the cutters are formed in the matrix by mounting graphite
formers in the mould before it is packed with the particulate material so as to define
sockets in the material, the formers being removed from the sockets after formation of
the matrix. Alternatively or additionally, the sockets may be machined in the matrix.
The cutters are usually secured in the sockets by brazing.

[0005]

In order to braze the cutters in place the cutters are located in their respective
sockets with a supply of brazing alloy. The bit body, with the cutters in place, is then
heated in a furnace to a temperature at which the brazing alloy melts and spreads by
capillary action between the inner surfaces of the sockets and the outer surfaces of the
cutters, an appropriate flux being used to facilitate this action.

[0006]

During the process of brazing the cutters to the bit body, the bit body must be
heated to a temperature which is usually in the range of 500°-750° and with the steels
hitherto used in the manufacture of the bit bodies of rotary drag-type bits, the
heating/cooling cycle employed during infiltration of the matrix and during brazing of
the cutters in position has the effect of reducing the hardness and strength of the steel.
In view of this, it has been the common practice to manufacture the steel mandrel of a
matrix bit in two parts. A first part is mounted within the mould so that the solid
infiltrated matrix may be bonded to it and the second part of the mandrel, providing the
threaded shank, is subsequently welded to the first part after the matrix has been formed
and after the cutters have been brazed into the sockets in the matrix. The part of the
mandrel providing the shank does not therefore have its hardness or strength reduced
by the brazing process nor by the heating/cooling cycle of the infiltration process.

[0007]

It would be desirable to avoid this necessity of welding a separate shank part to
the mandrel after formation of the matrix, since this not only adds to the cost of the
manufacturing process but the necessity of welding the parts together may compromise
the design of the bit body. For example, the bit body must be of sufficient length, and
so shaped, as to provide a region where the two parts can be welded together.
Accordingly, a one-piece mandrel could be shorter in length than a two-piece body and
this may have advantage, particularly where the drill bit is for use in steerable drilling
systems.

[0008]

Clearly, the necessity of subsequently welding a separate shank part to the
mandrel of the bit after formation of the matrix could be avoided if the mandrel were to
be formed from a material which was not reduced in hardness and strength during the
heating/cooling cycle employed during the brazing of the cutters on the drill bit. This
would enable the mandrel to be formed in one piece, including a portion to provide the
threaded shank of the drill bit.

[0009]

One type of material which might be used for this purpose is a precipitation
hardening alloy, such as a precipitation hardening steel or stainless steel. A
characteristic of a precipitation hardening alloy is that it hardens when subjected to an
appropriate heating/cooling cycle and it is therefore possible to control the
heating/cooling cycle to which the drill bit is subjected during brazing of the cutters on
the bit in such a manner as to harden the alloy of the mandrel.

[0010]

However, alloys of this type have different thermal characteristics from the
matrix formed around the mandrel in the manufacture of the matrix drill bit, and a result
of this mis-match of thermal characteristics may be a tendency for the matrix to crack
either during the cooling of the matrix and mandrel following the infiltration of the
matrix, or in the subsequent heating/cooling cycle for brazing the cutters to the bit body.

[0011]

The present invention sets out to overcome this problem while still permitting
the mandrel to include a portion to provide the threaded shank of the drill bit without
the necessity of welding such portion to the mandrel after formation of the matrix.

[0012]

According to the invention there is provided a method of manufacturing a rotary
drill bit of the kind comprising a bit body having a threaded connection region for
connection to a drill string and a leading face on which cutters are mounted, the method
including the step of locating a metal mandrel within a mould, packing the mould around
at least part of the mandrel with particulate matrix-forming material, infiltrating said
material at elevated temperature with a molten binding alloy, and cooling the material,
binding alloy and mandrel to form a solid infiltrated matrix bonded to the mandrel, the
mandrel being formed in at least two parts including an outer part surrounded by a main
body of said matrix-forming material and an inner part which engages with the outer part
of the mandrel and is out of contact with said main body of matrix-forming material.

[0013]

By forming the mandrel in two parts in this manner, the inner part of the mandrel
may have characteristics such that its strength and hardness are not reduced in the
infiltration process and the subsequent heating/cooling cycle for brazing the cutters on
to the drill bit. This not only strengthens the bit as a whole, but also allows the inner
part of the mandrel to include a portion to provide the threaded connection region of the
drill bit since the inner part of the mandrel will have sufficient strength and hardness for
this purpose. At the same time, the outer part of the mandrel may be selected from a
material having thermal characteristics closer to those of the main body of matrix, thus
reducing or avoiding the tendency for the matrix to crack under thermal stress.

[0014]

Accordingly, the inner part of the mandrel may be formed from a precipitation
hardening alloy, the method including the step of submitting the mandrel to a heating and
cooling cycle in a manner to effect precipitation hardening of the alloy from which the
inner part is formed. For example, the heating and cooling cycle may be that applied in
the infiltration process and/or in a process for subsequently brazing cutters to the bit
body.. The alloy may be a precipitation hardening steel. For example it may be a
martensitic or semi-austenitic type steel. It may be a stainless steel. However, the
invention is not limited to the use of steel or stainless steel for the inner part of the
mandrel and the use of other alloys and particularly precipitation hardening alloys is
contemplated, for example nickel based alloys. The outer part of the mandrel may be
formed from a non-precipitation hardening alloy.

[0015]

As is well known, a precipitation hardening alloy is an alloy in which very fine
particles of constituents of the alloy may be caused to precipitate, i.e. initiate and grow
from the parent alloy, so as to harden and strengthen the alloy. Such precipitation may
be effected by subjecting the alloy to a controlled heating and cooling cycle.

[0016]

The initiation and growth of precipitates ("precipitation") is a diffusion process,
i.e. it is controlled by time and temperature. A certain threshold amount of energy is
required to trigger initiation. In certain alloys, there is sufficient energy at room
temperature to trigger initiation; albeit at a very slow pace. In the majority of alloys,
however, an elevated temperature, and a minimum time at that temperature, is required
to trigger initiation.

[0017]

The size of the precipitates is critical to the degree of hardness, strength, and
ductility obtained. The precipitation hardening effect arises from the precipitates causing
local distortion of the crystal lattice. The greatest hardness (and the lowest ductility) is
achieved when the precipitates are numerous and exceptionally fine. As the temperature
is increased above a threshold temperature, larger and fewer particles are precipitated
and, as a result, hardness decreases and ductility increases. As the temperature is raised
further, there comes a point where the particles are too few and too large to contribute
appreciably to the hardness/strength of the alloy.

[0018]

A "solution" heat treatment in which the alloy is raised to an even higher
temperature, acts to "dissolve" the majority of existing precipitates, by taking them back
into the solid solution. Subsequent cooling to room temperature tends to lock the
precipitation hardening elements into solid solution. The faster the cooling rate, the
greater is this tendency. The slower the cooling rate, the more chance there is to initiate
and grow precipitates during the cooling cycle. The precipitates created during the
cooling cycle, from the higher temperature, tend to be less beneficial to increasing
hardness/strength than those created by a subsequent, separate, precipitation hardening
heat treatment.

[0019]

The overall aim, according to the invention, therefore, is to subject the alloy from
which the inner part of the mandrel is formed to a combination of time and temperature
which causes precipitation hardening and gives rise to the optimum hardness/ductility
combination. In theory, this may be achieved by first taking all the precipitates into
solution at a high "solution treatment" temperature; followed by fast cooling to room
temperature; followed by heating quickly to a lower precipitation hardening temperature
and holding at that temperature for a prescribed time; followed by a fast cool back to
room temperature. Precipitation hardening may also be effected by performing the latter
precipitation hardening step alone.

[0020]

As previously mentioned, the necessary heating/cooling cycle to effect
precipitation hardening of the inner part of the mandrel may be achieved by suitable
control of the heating/cooling cycles to which the bit body is subjected during
manufacture. For example, the heating/cooling cycle to which the bit body is subjected
during the infiltration process may be controlled so as to effect a preliminary "solution"
heat treatment prior to precipitation hardening effected by controlling the
heating/cooling cycle to which the bit body is subjected during brazing the cutters to the
bit body. However, the invention does not exclude methods where precipitation
hardening of the inner part of the mandrel is achieved by a separate heating/cooling cycle
unconnected with the normal stages of manufacture of the bit body.

[0021]

The outer part of the mandrel may be formed from a non-corrosion-resistant
steel. The steel may be what is known as a "Plain-Carbon" steel. For example, it may
be a steel of the grade identified as EN8 and having a carbon content in the range of
0.36% to 0.44%. Other suitable steels are grades identified as AISI1018, AISI1019,
AIAI1020, AISI1021 and AISI1022 having a carbon content in the range of 0.15% to
0.23%.

[0022]

The inner part of the mandrel may be engaged with the outer part of the mandrel
by any suitable method, including for example a threaded connection, an interference fit,
an adhesive or welding.

[0023]

Preferably there is provided between the inner and outer parts of the mandrel a
brazing gap which is filled with molten brazing alloy during the infiltration of the matrix-forming
material at elevated temperature, so as to braze the inner part to the outer part.
The brazing alloy may comprise part of the binding alloy which infiltrates the matrix-forming
material, but may also comprise a different alloy applied separately to the
brazing gap.

[0024]

The matrix-forming material packed around the mandrel may include a portion,
in addition to said main body of matrix-forming material, which engages a surface of the
inner part of the mandrel. For example, the inner part of the mandrel may include an
internal passage which is lined with matrix-forming material.

[0025]

In any of the above arrangements the inner part of the mandrel is preferably
coaxial with the outer part of the mandrel. For example, the inner part may have a
cylindrical portion which engages within a registering cylindrical socket in the outer part.

[0026]

The method may include the further step of machining an integral portion of the
inner part of the mandrel to form the threaded connection region of the drill bit.
Alternatively, a separately formed member may be welded or otherwise secured to the
inner part of the mandrel, after formation of the solid infiltrated matrix, to form the
threaded connection region of the drill bit.

[0027]

The threaded connection region of the drill bit may be defined by an externally
screw threaded shank forming part of the drill bit. Alternatively, the threaded
connection region may be defined by an internally screw threaded part of the drill bit, for
example in the form of a so-called box threaded connection.

[0028]

The invention also provides a rotary drill bit comprising a bit body having a
threaded connection region for connection to a drill string and a leading face on which
cutters are mounted, the bit body comprising a metal mandrel around part of the outer
surface of which is formed a layer of solid infiltrated matrix material, said mandrel
comprising an inner part formed of an alloy which has been precipitation hardened, and
an outer part formed from an alloy which has not been precipitation hardened.

[0029]

The following is a more detailed description of embodiments of the invention,
by way of example, reference being made to the accompanying drawings in which:

Figure 1 is a diagrammatic section through a prior art matrix-bodied drill bit,

Figure 3 shows diagrammatically the manufacture of a matrix-bodied drill bit by
a method according to the present invention,

Figure 4 is a diagrammatic section through a rotary drag-type drill bit according
to the invention, and

Figures 5 and 6 are views similar to Figures 3 and 4, illustrating an alternative
design of drill bit.

[0030]

Figure 1 shows a prior art matrix-bodied drill bit. The main body of the drill bit
comprises a leading part 10 and a connection region in the form of a shank part 12. The
leading part 10 includes a steel mandrel 14 having a central passage 16. The lower
portion of the mandrel 14 is surrounded by a body 18 of solid infiltrated matrix material
which defines the leading face of the drill bit and provides a number of upstanding blades
20 extending outwardly away from the central axis of rotation 22 of the bit. Cutters 24
are mounted side-by-side along each blade 20 in known manner. The passage 16 in the
mandrel 14 is also lined with solid infiltrated matrix and the passage communicates
through a number of subsidiary passages 26 to nozzles (not shown) mounted in the
leading surface of the bit body between the blades 20.

[0031]

The upper part of the mandrel 14 is formed with a stepped cylindrical socket 28
in which is received a correspondingly shaped projection 30 on the lower end of the
shank part 12. The shank part 12 is welded to the mandrel 14 as indicated at 32. The
shank part is formed, in known manner, with a tapered threaded pin 34 by means of
which the bit is connected to a drill collar at the lower end of the drill string, and breaker
slots 36 for engagement by a tool during connection and disconnection of the bit to the
drill collar.

[0032]

Figure 2 shows diagrammatically the manner of manufacture of the prior art bit
of Figure 1. The bit is formed in a machined graphite mould 38 the inner surface 40 of
which corresponds substantially in shape to the desired outer configuration of the leading
part of the bit body, including the blades 20.

[0033]

The metal mandrel 14, which is usually formed from steel, is supported within
the mould 38. Formers 42, 44 are located within the mould so as to form the central
passage in the bit body and the subsidiary passages leading to the nozzles. Graphite
formers 46 are also located on the interior surface of the mould to form the sockets into
which the cutters will eventually be brazed.

[0034]

The spaces between the mandrel 14 and the interior of the mould 38 are packed
with a particulate matrix-forming material, such as particles of tungsten carbide, this
material also being packed around the graphite formers 42, 44 and 46. Bodies 8 of a
suitable binder alloy, usually a copper based alloy, are then located in an annular
chamber around the upper end of the mandrel 14 and above the packed matrix-forming
material 50.

[0035]

The blades 20 of the bit may be entirely formed of matrix or metal cores may be
located in the mould at each blade location so as to be surrounded by matrix and thus
form a blade comprising a matrix layer on a central metal core.

[0036]

The mould is then closed and placed in a furnace and heated to a temperature at
which the alloy 48 fuses and infiltrates downwardly into the mass of particulate material
50. The mould is then cooled so that the binder alloy solidifies, binding the tungsten
carbide particles together and to the mandrel 14 so as to form a solid infiltrated matrix
surrounding the mandrel 14 and in the desired shape of the outer surface of the bit body.

[0037]

When the matrix-covered mandrel is removed from the mould, the formers 42,
44 and 46 are removed so as to define the passages in the bit body and the sockets for
the cutters, and the upper end of the mandrel 14 is then machined to the appropriate final
shape, as indicated by the dotted lines 52 in Figure 2.

[0038]

After machining of the mandrel 14 and brazing of the cutters 24 into the sockets
in the blades 20, the pre-machined steel shank part 12 is welded to the upper end of the
mandrel 14.

[0039]

In this prior art method of manufacture of a drill bit, the infiltration
heating/cooling cycle has the effect of reducing the hardness and strength of the steel
mandrel 14. Also, in order to braze the cutters 24 into their respective sockets on the
blades 20 the drill bit must also be subjected to a heating/cooling cycle in a furnace,
which also tends to reduce the hardness and strength of the mandrel 14. It is for this
reason that the shank part 12 of the drill bit is separately formed and subsequently
welded to the mandrel in order to avoid the shank part also being reduced in hardness
and strength as a result of the heating/cooling cycles.

[0040]

As previously explained, the necessity of having to weld the shank part to the
mandrel not only increases the cost of manufacture, but having to design the components
in a manner so that they can be welded together provides a constraint on the design of
the bit, and in particular on its minimum axial length. Accordingly, if such welding could
be avoided, the bit could be made shorter in axial length which may be desirable for
some usages, for example in steerable drilling systems.

[0041]

Figure 3 illustrates a modified method of manufacture according to the present
invention. Parts of the apparatus corresponding to parts shown in Figure 2 have the
same reference numerals.

[0042]

As in the prior art arrangement a metal mandrel 54 is supported within a mould
38, matrix-forming material 50 is packed into the spaces between the mandrel 54 and the
inner surface of the mould 38 and is infiltrated in a furnace by a molten binding alloy
provided by bodies 48 of the alloy located in an annular chamber surrounding the
mandrel 54.

[0043]

According to the present invention, however, the mandrel is formed in two parts
comprising an outer part 56 and an inner part 58. The inner part 58 is cylindrical and
is received in a corresponding cylindrical socket 60 in the outer part 54. A brazing gap
62 is formed between the inner and outer parts and, during the infiltration process,
molten alloy from the bodies 48 infiltrates into the brazing gap 62 so as to braze the
inner part 58 to the outer part 56.

[0044]

In the preferred embodiment of the invention the steel or other alloy from which
the inner part 58 of the mandrel is formed is a precipitation hardening alloy. As
previously described, when a precipitation hardening alloy is subjected to an
appropriately controlled heating/cooling cycle, particles of constituents of the alloy
precipitate and locally distort the lattice of the alloy at the microscopic level to create
local stress zones and thereby increase the hardness and strength of the material.

[0045]

One suitable form of alloy for use in manufacture of the inner part of the mandrel
is a 17-4 PH grade of martensitic precipitation hardening stainless steel having the
following chemical composition:

Weight %

Minimum

Maximum

Carbon

0.07

Silicon

1.00

Manganese

1.00

Phosphorus

0.04

Sulphur

0.03

Chromium

15.00

17.50

Molybdenum

0.50

Nickel

3.00

5.00

Niobium

5xC min

0.45

Copper

3.00

5.00

[0046]

The metal may be that which conforms to the following standard specifications:

AMS 5622 (remelt)

AMS 5643 QQ-S-763B

MIL-S-862B

MIL-C-24111 (Nuclear)

ASTM A564-72 Type 630

W.1.4548

NACE MR.01.75

[0047]

During the infiltration process the mandrel 54 is heated to a temperature of about
1160°C before being cooled to room temperature. During the heating part of this cycle,
the majority of any existing precipitates in the alloy are dissolved into solid solution.
During the subsequent cooling from the infiltration temperature, precipitates of
constituents of the alloy are formed in solution as the first stage of a precipitation
hardening process. When the bit body is subjected to a further heating/cooling cycle in
order to braze the cutters into the sockets in the matrix part of the bit precipitation
hardening is completed.

[0048]

The inner part 58 of the mandrel therefore becomes hardened as a result of the
processes to which the bit is subjected during manufacture and does not have its
hardness and strength reduced as is the case with the mandrels in prior art methods.
This allows the inner part of the mandrel 58 to be formed integrally in one piece with a
body 64 of the same material which may be subsequently machined to provide the
breaker slots and the threaded connection region which, in this case comprises a shank
having an externally threaded pin, as indicated by the dotted lines 66 in Figure 3.

[0049]

The outer part 56 of the mandrel 54 is preferably formed from a non-corrosion-resistant
steel which is a non-precipitation hardening steel, and may for example be any
of the plain-carbon steels previously mentioned.

[0050]

The outer part 56 of the mandrel will become reduced in hardness and strength
during the heating/cooling cycles to which the bit is subjected, but this will not matter
since it is separate from the different body of material 64 from which the shank of the
drill bit is formed. However, the outer part 56 of the mandrel may have thermal
characteristics which are closer to the thermal characteristics of the solid infiltrated
matrix than are the thermal characteristics of the inner part 58 of the mandrel. Any
tendency for the solidified matrix to crack during the heating/cooling cycles, as a result
of mis-match of thermal characteristics, is therefore reduced or eliminated.

[0051]

Although it is a major advantage of the present invention that it enables the shank
portion of the drill bit to be integral with part of the mandrel, thus avoiding the necessity
of subsequently welding the shank to the mandrel, the invention does not exclude
arrangements where the shank is subsequently welded to a two-part mandrel in
accordance with the present invention, since the inclusion of an inner part to the mandrel
which maintains its strength and hardness during manufacture will still enhance the
strength of the finished drill bit in any case, and this in itself is advantageous.

[0052]

Figure 4 shows a finished drill bit manufactured by the method according to the
present invention. Comparing this with Figure 1, it will be seen that, since there is no
necessity of welding the shank to the mandrel, the breaker slots 36 on the shank are
much closer to the leading face of the bit than they are in the prior art arrangement, and
the overall axial length of the bit is therefore reduced.

[0053]

Figure 6 illustrates an alternative design of rotary drill bit, Figure 5 illustrating,
diagrammatically, the method of manufacture of the drill bit. The drill bit of Figure 6 is
very similar to that of Figure 4, and the like reference numerals will be used to denote
like parts. Further, only the significant differences between the drill bit of Figure 6 and
that of Figure 4 will be described.

[0054]

In the arrangement of Figure 6, the outer part 56 of the mandrel 54 is provided
with or defines a socket 60 of generally frusto-conical form rather than of generally
cylindrical form as in the drill bit of Figure 4. The inner part 58 is of generally frusto-conical
form and is received within the socket 60. The inner part 58 is of tubular form,
the inner surface of the inner part 58 being provided with a screw thread formation
whereby the drill bit can be connected to a drill string in a box thread type manner.

[0055]

A further distinction between the arrangement of Figure 4 and that of Figure 6
is that, for a drill bit of given axial extent, the outer part 56 of the mandrel 54 can be of
increased axial extent in the arrangement of Figure 6 compared to that of Figure 4, and
the axial length of the main body of the matrix material formed part of the drill bit can
be increased. The increase in the axial length of the main body permits the breaker slots
36 to be formed in the matrix material formed part of the drill body rather than in the
outer part 56 of the mandrel 54, and permits an increase in the gauge length of the bit
without increasing the length of the bit.

[0056]

The method of manufacture of the drill bit follows the method described
hereinbefore with reference to the drill bit of Figure 4 with the exception that, prior to
introducing the matrix-forming material into the mould, an insert is positioned in the
mould to form the breaker slots 36 in the drill bit body.

[0057]

After the moulding operation has been completed, the inner part 58 of the
mandrel 54 is machined to form the screw thread therein. In an alternative arrangement,
a separate component defining a box thread connection may be secured, for example by
welding, to the mandrel 54.

[0058]

Other suitable forms of precipitation hardening alloys which may be used in the
invention are 15-5 PH grade and 520B grade stainless steels having the following typical
compositions.

15-5PH Grade:

[0059]

Weight %

Minimum

Maximum

Carbon

0.07

Silicon

1.00

Manganese

1.00

Phosphorus

0.03

Sulphur

0.015

Chromium

14.00

15.50

Molybdenum

0.50

Nickel

3.50

5.50

Niobium

5xC min

0.45

Copper

2.50

4.50

[0060]

The metal may be that which conforms to the following standard specifications:

AMS 5659 (remelt)

ASTM A630 Type XM12

520B Grade:

[0061]

Weight %

Carbon

0.05

Chromium

14.00

Molybdenum

1.70

Nickel

5.60

Niobium

0.30

Copper

1.80

[0062]

The metal may be that which conforms to the following standard specifications:

BS.5143

BS.5144

[0063]

Other proprietary grades of stainless steel may be used allowing up to 3%
Molybdenum, 0.15% carbon 8% nickel and down to 13% chromium.

[0064]

Semi-austenitic precipitation hardening stainless steels may also be employed,
including 17-7 PH grade stainless steel having the following composition:

Weight %

Carbon

0.07

Chromium

17.0

Nickel

7.0

Aluminium

0.4

Titanium

0.4 to 1.2

[0065]

Other proprietary grades of semi-austenitic precipitation hardening stainless
steels may be used, in grades allowing up to 0.2% carbon, 2% copper, 3% molybdenum,
2% cobalt, 1.2% aluminium, 2% cobalt, 0.3% phosphorus and down to 12% chromium
and 3.5% nickel. All percentages are by weight.

[0066]

Although the specific alloys described in this specification are steel, and this is
preferred, the present invention does not exclude the use of other precipitation hardening
alloys in the manufacture of the inner part of the mandrel.

Claims (27)

A method of manufacturing a rotary drill bit of the kind comprising a bit body
having a threaded connection region for connection to a drill string and a leading face
on which cutters (24) are mounted, the method including the step of locating a metal
mandrel (54) within a mould (38), packing the mould (38) around at least part of the
mandrel (54) with particulate matrix-forming material (50), infiltrating said material (50)
at elevated temperature with a molten binding alloy, and cooling the material (50),
binding alloy and mandrel (54) to form a solid infiltrated matrix bonded to the mandrel
(54), the mandrel (54) being formed in at least two parts including an outer part (56)
surrounded by a main body of said matrix-forming material (50) and an inner part (58)
which engages with the outer part (56) of the mandrel (54) and is out of contact with
said main body of matrix-forming material (50).

A method according to Claim 1, wherein the inner part (58) of the mandrel (54)
is formed from a precipitation hardening alloy, the method including the step of
submitting the mandrel (54) to a heating and cooling cycle in a manner to effect
precipitation hardening of the alloy from which the inner part (58) is formed.

A method according to Claim 2, wherein the heating and cooling cycle is that
applied in the infiltration process.

A method according to Claim 2, wherein the heating and cooling cycle is that
applied in a process for subsequently brazing cutters (24) to the bit body.

A method according to Claim 2, wherein the heating and cooling cycle is that
applied both in the infiltration process and in a process for subsequently brazing cutters
(24) to the bit body.

A method according to any one of Claims 2 to 5, wherein the precipitation
hardening alloy is a precipitation hardening alloy steel.

A method according to Claim 6, wherein the precipitation hardening alloy is
selected from a martensitic and semi-austenitic type steel.

A method according to Claim 6, wherein the precipitation hardening alloy is a
stainless steel.

A method according to any one of Claims 2 to 5, wherein the precipitation
hardening alloy is a nickel based alloy.

A method according to any one of Claims 2 to 9, including the step of heating
the precipitation hardening alloy quickly to a precipitation hardening temperature and
holding at that temperature for a prescribed time; followed by a fast cool back to room
temperature.

A method according to any one of Claims 2 to 9, including the steps of first
taking all the precipitates in the alloy into solution at a high "solution treatment"
temperature; followed by fast cooling to room temperature; followed by heating quickly
to a lower precipitation hardening temperature and holding at that temperature for a
prescribed time; followed by a fast cool back to room temperature.

A method according to Claim 3, wherein the heating/cooling cycle to which the
bit body is subjected during the infiltration process is controlled so as to effect a
preliminary "solution" heat treatment prior to precipitation hardening effected by
controlling the heating/cooling cycle to which the bit body is subjected during brazing
the cutters (24) to the bit body.

A method according to any one of the preceding claims, wherein the outer part
(56) of the mandrel (54) is formed from a non-corrosion-resistant steel.

A method according to Claim 13, wherein the outer part (56) of the mandrel (54)
is formed from a plain-carbon steel having a carbon content in the range of 0.36% to
0.44%.

A method according to any one of the preceding claims, wherein the inner part
(58) of the mandrel (54) is engaged with the outer part (56) of the mandrel (54) by a
method selected from: a threaded connection, an interference fit, an adhesive, welding.

A method according to any one of Claims 1 to 14, wherein there is provided
between the inner and outer parts (56, 58) of the mandrel (54) a brazing gap (62) which
is filled with molten brazing alloy during the infiltration of the matrix-forming material
(50) at elevated temperature, so as to braze the inner part (58) to the outer part (56).

A method according to Claim 16, wherein the brazing alloy comprises part of the
binding alloy which infiltrates the matrix-forming material (50).

A method according to any one of the preceding claims, wherein the matrix-forming
material (50) packed around the mandrel (54) includes a portion, in addition to
said main body of matrix-forming material (50), which engages a surface of the inner
part (58) of the mandrel (54).

A method according to Claim 18, wherein the inner part (58) of the mandrel (54)
includes an internal passage which is lined with matrix-forming material.

A method according to any one of the preceding claims, wherein the inner part
of the mandrel (54) is coaxial with the outer part (56) of the mandrel (54) and has a
portion which engages within a registering socket (60) in the outer part (56).

A method according to any one of the preceding claims, including the further
step of machining an integral portion of the inner part (58) of the mandrel (54) to form
the threaded connection region of the drill bit.

A method according to any one of Claims 1 to 20, including the further step of
securing a separately formed member to the inner part (58) of the mandrel (54), after
formation of the solid infiltrated matrix, to form the threaded connection region of the
drill bit.

A method according to any one of the preceding claims wherein the threaded
connection region comprises an externally screw threaded shank.

A method according to any one of Claims 1 to 22, wherein the threaded
connection region comprises an internally screw threaded part of the drill bit body.

A rotary drill bit comprising a bit body having a threaded connection region for
connection to a drill string and a leading face on which cutters (24) are mounted, the bit
body comprising a metal mandrel (54), around part of the outer surface of which is
formed a main body of solid infiltrated matrix material (50), said mandrel (54)
comprising an outer part (56) surrounded by said main body of solid infiltrated matrix
material (50), and an inner part (58) which engages the outer part (56), said inner part
(58) being formed of an alloy which has been precipitation hardened.

A rotary drill bit according to Claim 25, wherein said inner part (58) of the
mandrel (54) is out of contact with said main body of solid infiltrated matrix material
(50).

A rotary drill bit according to Claim 25 or Claim 26, wherein said threaded
connection region of the drill bit is integral with said inner part (58) of the mandrel (54).